Procedure B - For E65/E66 (7 Series) Basic Seat Only

1. Removal of seat cover from foam backrest pad.

Completely disconnect the seat cover from all of the metal hooks on the back side of the metal seat frame. Once they are all unhooked, pull the bottom of the seat cover towards the front of the vehicle to provide more slack at the top. Then, while leaving the seat cover attached to the foam pad, lift the seat cover and foam pad together up and over the backrest frame. Once the seat cover and foam pad are removed from the backrest frame, separate the cover from the foam by pushing down to compress the foam and then flip the seat cover forwards, over the top of the foam backrest pad.





2. Fold the top portion of the seat cover (1) forwards, away from the foam backrest pad (2).





Note:
Drivers seat shown.

3. Mark the following dimensions on the cloth material of the seat cover (1).
A1: approximately 70 mm (from the door side seam to level with the middle of the head restraint hole).
A2: approximately 150 mm (from the upper edge of the cotton fabric). Note: drivers seat shown for this procedure.





4. Using a seam ripper, cut the cotton fabric open along the marking (dimension A2). Make incision (1) in the same way.

5. Turn the cotton fabric over and expose the padding.





6. Draw guide lines (2) on the door side approximately 20 mm from seams (1) on padding (3).

7. Cut into the guide lines and fold the padding to one side. Cut into the padding carefully to avoid damage to the backrest heating.





8. Mark the following dimensions on the backrest heating pad:
A3: approximately 30 mm (from the start of the backrest heating pad on the door side).
A4: approximately 30 mm (from dimension A3).





9. Cut open the backrest heating pad along the length of the marking (dimension A4) to expose all 11 metal strands, widen the cut if necessary. Note: Cut into the backrest heating carefully to avoid damage to the cover surface material.





10. From the corners of the cut made above, cut parallel incisions to the left and right of the metal strands.

Note: Be careful when cutting along dimension A4 to only cut into the first ply.
A4: approximately 50 mm long.
A5: approximately 40 mm long.





11. Peel back the first ply of the heating pad (1) to expose the metal strands (2).





12. Carefully pull up on each metal strand (1), using the blunt side of the seam ripper (2), to release them from the fabric threads. Start pulling up on the metal strands near the cut made for dimension A4. Continue until at least 30 mm of each of the metal strands has been released from the fabric threads.
Note: The metal strands remain attached to the fleece near the bottom fold of the first ply.
Be careful not to damage the metal strands when pulling them away from the threads. It may be necessary to cut some of the treads to release the metal strands.
Note: Illustrations in steps 12 through 19 are shown of the passenger side seat.





13. Once the 11 metal strands are released from the material, fan out the strands to make them ready to splice with the wire from the repair kit.





14. Strip the wire (1) from the repair kit (copper-colored end) and fan out the strands. Join the copper strands to the 11 metal heating strands and twist them together.





15. Twist the wires together tightly to form one slender splice of both sets of wires.





16. Push the crimp from the kit over the twisted strands with the larger diameter first.





17. Crimp (1) using special tool (2) number 52 0 100. Cut off the protruding strands end of the sleeve.





18. Affix the small fleece adhesive strip (1) (60 mm x 40 mm), from the repair kit over the padding where the cut was made.





19. Using a hot glue gun, apply glue to small fleece adhesive strip (1) and affix crimped strands to the glue.
To secure, press a hammer onto glue (2) for at least one minute.
Note:
Do not use an excessive amount of glue and be sure to press firmly with the hammer. Failure to do so may result in a bump in the leather when the procedure is completed.

20. Fold the upper ply of the backrest heating pad (cover surface material side) back into the cutout. Affix the small fleece adhesive strip (60 mm x 40 mm) under the padding and over the cutout and upper ply of the backrest heating.

21. Fold the strand backing material and rear backrest heating ply onto the repair area.

22. Affix another small fleece adhesive strip (60 mm x 40 mm) to the repair area under the padding.





23. Cut a small hole into the padding near the new wire (as indicated by the arrow) and then pull the wire through loosely.

24. Fold back the padding and seal the incisions using a large fleece adhesive strip (170 mm x 55 mm).

25. Turn the cotton fabric over and affix using a large fleece adhesive strip (170 mm x 55 mm). Route the wire on the door side.

26. Continue to procedure D: For All Seats.